Integrated photovoltaic module mounting system for use with tufted geosynthetics

ABSTRACT

A mounting system 110 for a solar panel 11 includes a base plate 114 having an elongated mounting slot 116, a spacer beam 124 with a slot 128, a first T-shaped fastener 131 having a mounting plate 132 with a width slightly smaller than the size of the slot and a length larger than the size of the slot, so that the mounting plate may be passed through the slot and then rotated so that it then cannot pass back through the slot. A second T-shaped fastener 137 having the same configuration couples the solar panel to the spacer. The system optionally has a ballast system 145 which includes a ballast tray 146 and third T-shaped fastener 155 of the same configuration for coupling the tray to the base plate. An anti-creep strip 161 is coupled to the base member through fourth T-shaped fasteners 162 of the same configuration.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 62/616,705 filed Jan. 12, 2018 and entitledIntegrated Photovoltaic Module Mounting System For Use With TuftedGeosynthetics. This application also claims the benefit of U.S.Provisional Patent Application Ser. No. 62/522,402 filed Jun. 20, 2017and entitled Integrated Photovoltaic Module Mounting System For Use WithTufted Geosynthetics.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

TECHNICAL FIELD

This invention relates to an integrated mounting system for photovoltaicmodules for use in solar energy collection. In a more specific aspect,this invention relates to a non-ballasted and non-ground penetratingintegrated photovoltaic mounting system for use with, and supported by,tufted geosynthetics.

In this application, the following terms will be understood to have theindicated definitions:

-   -   “photovoltaic module”—a module which utilizes the generation of        voltage when radiant energy (such as solar energy) falls on the        module; sometimes referred to as a solar cell.    -   “tufted geosynthetics”—a system which is adapted to cover waste        sites and other environmental closures and which is generally        comprised of synthetic grass having synthetic fibers tufted to a        backing and a geomembrane. Examples of a tufted geosynthetic        cover system are shown in Ayers and Urrutia U.S. Pat. Nos.        7,682,105 and 9,163,375. The term “tufted geosynthetics” is also        used to refer to a synthetic turf cover system.    -   “synthetic grass”—refers to a composite which comprises at least        one geotextile (woven or nonwoven) tufted with one or more        synthetic yarns or strands and which has the appearance of        grass.    -   “geomembrane”—refers to a polymeric material, such as high        density polyethylene, very low density polyethylene, linear low        density polyethylene, polyvinyl chloride, etc.    -   “surface”—refers to a surface which has an angle of slope of        zero or more.    -   “creep”—refers to a behavior of materials (such as soils and        geosynthetics) to move or deform slowly under a constant load or        stress.

BACKGROUND OF THE INVENTION

Photovoltaic solar modules have historically been mounted by use of arigid racking system over a variety of surfaces such as rooftops,greenfields and brownfields. These rigid racking systems have not beenintegrated onto the photovoltaic module. Typical systems include rackingstructures that the photovoltaic module must be placed upon and thenmechanically fastened to the racking structure.

Racking structures are placed in spaced-relation and the rackingstructures enable orienting the photovoltaic module at anenergy-generating efficient angle. However, the spacing limits thenumber of photovoltaic modules that can be installed in an area becausethe angling causes shadows. An adjacent rack must be spaced sufficientlythat the photovoltaic modules are not within a shadow area.

There is a need in the solar industry for an integrated photovoltaicmodule in which the mounting mechanism is attached to the photovoltaicmodule which eliminates the need for a rigid racking system. Theintegration allows for an economical alternative to a traditional rigidracking system and enables the increasing of the density of thephotovoltaic modules placed at a solar energy generation site, therebyincreasing the potential generation of electrical power while allowingflexibility of installation by using non-traditional racking installers.

While use of solar as a renewable alternative energy source has “cleanenergy” favorabilities, there are drawback to such installations. Solarenergy generation sites typically require large tracts of land. In somelocation circumstances, wooded lands are cleared or farm lands arere-purposed for use as solar energy generation sites. Other sites aresignificantly remote from tie-in connections to the power transmissionand distribution grid of power generating and supply companies. Theseremote sites require capital expenditures to install and maintaintransmission lines to the electrical grid and such transmission linesoccupy additional land. Also, recent changes in power generationcapacity has decreased reliance on coal and increased reliance oncleaner combustion fuels such as natural gas and, alternatively, powerplants that generate electricity with turbines operated with steamheated by nuclear fuel sources. The coal-fired power plants neverthelesshave large areas of ash holding ponds or storage areas. These areas aresubject to closing with covers such as geomembranes that restrictenvironmental waters, such as rain or other precipitation or surfacewater flow, from passing through the covered site and leaching into theground or pond.

Accordingly, there is a need in the art for an improved integratedmounting system for securing photovoltaic modules to a surface forgenerating solar power. It is to such that the present invention isdirected.

SUMMARY OF THE INVENTION

The integrated mounting system of this invention allows for easyinstallation supported by a tufted geosynthetic on a surface. Thiscombination of the integrated mounting system and tufted geosyntheticresults in a lower cost, lower maintenance of the surrounding surface,adaptable for variety of grades from flat to sloping ground andgenerates more solar power per unit area.

Briefly described, the present invention integrates a photovoltaicmodule mounting system over tufted geosynthetics on various surfaces(such as a ground cover system, roof, reservoir, pond, etc.). There aretwo preferred components of this invention that may be combined or usedseparately within the integrated photovoltaic module mounting system andwithin any combination thereof.

The first component is one or more anti-creep strip(s) that enhancesinterface friction between the photovoltaic module and the tuftedgeosynthetic, while also reducing shearing forces between thephotovoltaic module and its mounting surface, thus preventing orsubstantially preventing sliding forces from mobilizing the module. Ifdesired, a monitoring device can be used to measure the amount of creep.

The second component is a flexible attachment connection which is used,in addition to the anti-creep strip(s), as an additional factor toincrease interface friction and to counter potential shearing and upliftforces which could be caused by high wind gusts. The attachmentconnection can be welded directly to the tufted geosynthetic or thegeomembrane and attached to the bottom, top or side of the photovoltaicmodule. Other means of attaching the connection to the geosyntheticinclude mechanical means (e.g., screws, bolts, etc.) and adhesive meanssuch as glue, tape, etc.

These two components eliminate the need for ballast compared to atraditional photovoltaic racking system which does not have foundationanchoring. The integrated photovoltaic module mounting system supportedby a tufted geosynthetic requires no ballast on a surface. These twocomponents enable multiple configurations (as shown in the drawings).

The result of a non-ballasted integrated photovoltaic module mountingsystem allows for a lower cost and increased power generation throughhigher density of module placement at an energy generation site Anadditional advantage of an integrated photovoltaic module mountingsystem is that the system does not require grounding.

The integrated photovoltaic module mounting system of this inventionallows for a higher density (i.e., one or more) of photovoltaic modulesin a defined area as compared to traditional systems, and a higherdensity of modules enables the integrated photovoltaic module mountingsystem to provide more electrical power per unit area.

More particularly described, the present invention meets the need in theart by providing an integrated photovoltaic module mounting system foruse in mounting a photovoltaic module to tufted geosynthetics,comprising at least one elongated base plate and at least one elongatedrail, said elongated rail coupled to and longitudinally aligned withsaid base plate with a plurality of rail fasteners coupling said baseplate and said elongated rail. A plurality of photovoltaic modulefasteners for coupling said rail with the photovoltaic module, and ananti-creep strip coupled to a bottom surface of said base plate.

In another aspect, the present invention provides an integratedphotovoltaic module mounting system for use in mounting a photovoltaicmodule to tufted geosynthetics, comprising at least one elongated railand a plurality of first fasteners for coupling said rail with thephotovoltaic module, and an anti-creep strip coupled to a bottom surfaceof said rail.

In yet another aspect, the present invention provides an integratedphotovoltaic module mounting system for use in mounting a photovoltaicmodule to tufted geosynthetics, comprising at least one elongated baseplate, said base plate having a base member, two opposing side wallseach having an inwardly extending lip to define a base plate slottherebetween having a selected slot width, with a plurality of firstfasteners for coupling said base plate with the photovoltaic module,said first fasteners having a mounting plate with a selected width lessthan said selected slot width and a selected length greater than saidselected slot width. An anti-creep strip couples to a bottom surface ofsaid base plate, said anti-creep strip including a support and aplurality of projections depending downwardly from said support.

In yet another aspect, the present invention provides a method ofmounting a photovoltaic module for use with tufted geosynthetics,comprising the steps of:

(a) coupling an anti-creep strip to a bottom surface of an elongatedrail;

(b) positioning the anti-creep strip onto a portion of a tuftedgeosynthetics covering a surface; and

(c) coupling a photovoltanic module to the elongated rail, wherein thephotovotanic module generates electricity and the anti-creep stripinter-engaged with the tufts of the tufted geosynthetics resists winduplift.

Objects, advantages and features of the present invention will becomeapparent upon a reading of the following detailed description inconjunction with the drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows multiple flexible attachment connections (i.e., single weldharnesses) mounted on a photovoltaic module.

FIG. 1A shows a detailed bottom view of a single flexible attachmentconnection exploded away from a mounting baseplate attached tophotovoltaic solar module.

FIG. 2 is a view of multiple weld harness strips mounted on aphotovoltaic module.

FIG. 3 is a view of two anti-creep strips mounted on a photovoltaicmodule.

FIG. 4 is a view of multiple single weld harnesses used with multipleanti-creep strips.

FIG. 5A is a view of two weld harness strips used with multipleanti-creep strips.

FIG. 5B shows two weld harness strips used with a single anti-creepstrip.

FIG. 5C shows two weld harness strips used with multiple anti-creepstrips and multiple single weld harnesses.

FIG. 6 shows a cross section of a single weld harness strip used with aphotovoltaic module.

FIG. 6A illustrates in side elevational view an embodiment of thephotovoltaic module mounting system using a tilting device for selectiveorienting at an angle to the geosynthetic for optimal positioningrelative to the sun for energy generation.

FIG. 7 shows a top view of a single weld harness.

FIG. 8 is a perspective view of the mounting system in another preferredform.

FIG. 9 is a perspective view of the mounting system in another preferredform.

FIG. 10 is a side view of a portion of the mounting system of FIG. 9.

FIG. 11 is a side view of the mounting system in another preferred form.

FIG. 12 is a top view of the mounting system of FIG. 11, shown withmultiple solar panels mounted together.

FIG. 13 is a perspective view of the mounting system in yet anotherpreferred form.

FIG. 14 is an end view of a wiring tray system for solar panels in apreferred form.

FIG. 15 is a side view of the wiring tray system of FIG. 14.

FIG. 16 is an exploded end view of the wiring tray system of FIG. 14.

FIG. 17 is a perspective view of a mounting system in yet anotherpreferred form.

FIG. 18 is an exploded, end view of the mounting system of FIG. 17.

FIG. 19 is an end view of the mounting system of FIG. 17 shown with thespacer removed.

FIG. 20 is a top view of a portion of the mounting system of FIG. 17.

FIG. 21 is a perspective view of an alternate embodiment of a rail foruse with photovoltaic module mounting system in yet another preferredform.

DETAILED DESCRIPTION

The present invention provides an integrated photovoltaic modulemounting system for use with a tufted geosynthetic system on a surfacewithout a racking structure and without ballast for support.

The essential components of this invention are a tufted geosyntheticsystem and one or more integrated photovoltaic module mounting systems.

Cover System

Examples of tufted geosynthetic systems useful in the integratedphotovoltaic module mounting system of this invention are the coversmarketed by Watershed Geosynthetics LLC under the registered trademarksClosureTurf and VersaCap. These covers 11 comprise a composite of atleast one geotextile 213 which is tufted with a plurality ofspaced-apart tufts 215 with one or more synthetic yarns (i.e., a tuftedgeosynthetic) to simulate grass blades in a synthetic grass, and animpermeable geomembrane 217 comprised of a polymeric material.

The synthetic grass blades of the system may contain an infill materialand/or a material for protection of the synthetic grass blades againstultraviolet rays.

Solar Module

One or more mono- or multi-crystalline solar modules can be used in theintegrated photovoltaic module mounting system of this invention, suchas commercially available polycrystalline silicon solar modules.Examples of effective solar modules are available from BYD (China) underthe designation BYD 260P6C-30-DG and from Irina (China) under thedesignation Solar Duomax TSM-PEG14, Tallmax PE14A, and BYD P6C-36. Analternate embodiment discussed below gainfully uses a bifacial solarmodule.

Referring now to the drawings, in which like numerals represent likeelements, FIG. 1 shows in top view multiple single weld harnesses 1secured by a mounting baseplate 2 attached to a solar module 3. The weldharnesses 1 or tabs that extend flexibly laterally from a side edge ofthe solar module 3 and attach to at least some of the plurality of tufts215. The attaching may be accomplished by mechanically attached such aswith a fastener, chemically attached, welding (heat or sonic), orthermoset bonding.

FIG. 1A shows a detailed bottom view in which a single flexible weldharness 1 is exploded away from the mounting baseplate 2 that attaches,such as with adhesive 9, to a bottom surface of the photovoltaic solarmodule 3. The flexible weld harness 1 has a first portion 19 thatdefines an opening 12 for receiving a fastener such as a screw or boltthat engages a threaded passage 23 in the baseplate 2. The threadedpassage 23 extends in a raised spacer portion 21 of the baseplate 2,such as a nut mounted therein. A second portion 22 of the flexibleattachment connection 1 extends laterally as a flap to overlie andconnect (by mechanically linking with a fastener, chemically connecting,heat or sonic welded, thermoset bond or attached, or adhesive) to aportion of a tufted geosynthetic ground cover 11.

Instead of a tab 1 for the weld harness, FIG. 2 shows multiple elongatedweld harness strips 4 secured by the respective mounting baseplates 2attached to the solar module 3.

FIG. 3 shows two anti-creep strips 5 secured by the respective mountingbaseplates 2 attached to solar module 3.

FIG. 4 shows multiple single weld harnesses 1 in combination withanti-creep strips 5, both secured by mounting baseplate 2 attached tosolar module 3.

FIG. 5A shows two weld harness strips 4 in combination with anti-creepstrips 5 secured by mounting baseplate 2 attached to solar module 3.

FIG. 5B shows two weld harness strips 4 used with single anti-creepstrip 5 secured by mounting baseplate 2 attached to solar module 3.

FIG. 5C shows two weld harness strips 4 used with multiple anti-creepstrips 5 and secured by mounting baseplate 2 attached to solar module 3.

FIG. 6 shows a side elevational view of a single weld harness 1 securedto solar module 3.

FIG. 6A illustrates in side elevational view an embodiment of thephotovoltaic module mounting apparatus using a tilting device generally223 for selective orienting of the photovoltaic module 3 at an angle ato the geosynthetic cover 11 for optimal positioning relative to the sunfor energy generation.

FIG. 7 shows a top view of a single weld harness 1 having a single weldattachment in combination with wind disturbing openings 6 and openings 7for attaching optional mechanical connections.

Friction

This invention also provides a method for a non-ballasted modulemounting system utilizing one or more anti-creep strips 5 integrated onthe photovoltaic module when mounted over tufted geosynthetics, byincreasing the coefficient of friction between the anti-creep strips andthe tufted geosynthetic. The anti-creep strips 5 include a plurality ofspaced-apart feet 46 depending from a bottom surface. The feet 46inter-engage with the tufts 215 to provide frictional connection of thephotovoltaic solar module 3 to the tufted geosynthetic cover 11. In theillustrated embodiment, the anti-creep strips 5 connect to the mountingplate 2 using a threaded fastener to engage the threaded passageway 23in the baseplate 2. In embodiments that uses both the anti-creep strips5 and the weld harness 1 (or elongated attaching strip 4), the fastenerextends through the anti-creep strip and the weld harness and threadablyengages the passage 23. Alternatively, separate, or additionalbaseplates 2 may be used.

The anti-creep strips footing is generally a structured geomembrane ortufted geosynthetic cover 11.

The anti-creep strips, when used in this invention, comprise a polymericmaterial such as polyethylene, polypropylene, ethylene propylene dienemonomer, rubber, metal, textured metal, polyvinyl chloride,polyurethane, etc.

Further, an alternate embodiment may charge the geosynthetic cover 11with ballast infill 221, to provide a mass that increases the frictionalresistance to movement with the plurality of particles of the infillthat fill interstices and spaces above the geotextile 213 and among thetufts 215. When used in this invention, suitable materials for infillare sand, concrete and materials available from Watershed GeosyntheticsLLC (Alpharetta, Ga.) under the trademarks HydroBinder and ArmorFill.Infill can be of various colors, sizes and textures.

When used in this invention, examples of suitable materials foranti-creep strips are calendared, textured and structural membranes madeby Agru America, Inc. under the trademark SureGripnet.

Wind Uplift Resistance

The present invention comprises a wind-resistant non-ballastedintegrated photovoltaic module mounting system for use on a tuftedgeosynthetic, which preferably includes both anti-creep strips and anattachment layer. The system does not rely on weight to resist windforces, but instead relies on wind-breaking turf blades (i.e., thesynthetic grass) and an attachment to the turf blades (synthetic grass).The cover of the present invention can be deployed over a large areawith very minor ballasting. Wind-breaking elements 219 may also beutilized to break up the airflow over the integrated photovoltaic moduleto provide wind uplift resistance. As illustrated in FIG. 6, one or morewind breaking elements generally 219 may attach to an edge of thephotovoltaic module 3. The wind breaking elements 219 comprise aplurality of thin spaced-apart pins that extend upwardly, for example,about 1-12 inches, preferably about 2-6 inches, and more preferably,about 2-3 inches. In an alternate embodiment, the weld harness 4 mayinclude wind breaking or disturbing openings 6.

With this invention, the wind velocity on the impermeable surface(geomembrane) becomes turbulent near the surface of the cover, thusgreatly reducing the actual wind velocity at the liner surface anddecreasing associated uplift. The reaction of the synthetic grass of thetufted geosynthetic to the wind forces can also create a downward forceon the geomembrane. This reaction is caused by the filaments of thesynthetic grass applying an opposing force against the wind which istransferred as a downward force on the geomembrane.

The integrated photovoltaic module of this invention can be used with anoptional tilting device to raise or lower the module for better resultsdepending on the location. FIG. 6A illustrates in side elevational viewan embodiment of the photovoltaic module mounting apparatus using thetilting device generally 223 for selective orienting of the photovoltaicmodule 3 at an oblique angle a relative to the geosynthetic cover 11 foroptimal positioning relative to the sun for energy generation. Thetilting device 223 comprises at least a pair of the mounting base plates2 a, 2 b having riser portions 21 a, 21 b of different lengths, wherebythe photovoltaic module 3 is disposed at the angle a to the geosyntheticcover 11, for optimal energy generation.

Further, the mounting baseplate 2 spaces the photovoltaic solar module 3from the tufted geosynthetic ground cover 11. The spacing therebycreates a gap between the tufted geosynthetic ground cover and thephotovoltaic solar module 3, which gap facilitates air flow therealongfor heat dissipation in that heating of the photovoltaic solar module 3which occurs reduces the solar generation efficiency of the solarmodule. In an alternate embodiment, the mounting base plate 2 is sizedto provide at least an 18 inch to 24 inch gap under the photovoltaicsolar module 3. To further enhance solar generation energy capacity, thephotovoltaic solar module 3 is bifacial and the tufted geosyntheticground cover 11 includes light reflective features, such reflectantsadded into the polymeric used the extrusion of the yarn from which thetufts 215 are formed during tufting. As shown in FIG. 1, tuft 215 aillustrates a reflectant 216, for example, a small light-reflecting bodyor chip. Further, a light reflective color pigment material may beincluded in the polymeric to enhance reflectivity of ambient light fromthe tufted geosynthetic ground cover 11 proximate the photovoltaic solarmodule 3. For example, tufts 215 b are tufted with yarns that include acoloring pigment 218.

With reference next to FIG. 8, there is a shown a mounting system 10 inanother preferred form of the invention. The system 10 is shown mountedto a double glass photovoltaic module or solar panel 11. The system 10includes an elongated base plate 14 having an elongated mounting channel16 defined by a generally planar, elongated base member 17, twooppositely disposed elongated, vertically oriented channel walls 18having inwardly extending clamping tangs 19, and an elongated,vertically oriented central support wall 20. The system also includes anelongated I-beam or rail 24 having a horizontal lower member 25, ahorizontal upper member 26 and a vertical spanning member 27 extendingbetween the lower member 25 and upper member 26. The I-beam 24 isselectively, releasably coupled to and slideable relative to theunderlying base member 17 for slideable movement therebetween through aforce placed upon the I-beam 24. The clamping tangs 19 of the channelwalls 18 abut the top surface of the lower member 25 while the lowermember rests upon the central support wall 20, thereby holding theI-beam 24 in place relative to the base plate 14.

A C-shaped bracket 30 is slidably coupled to the upper member 26 forselective longitudinal movement along the upper member 26. The C-shapedbracket 30 includes a threaded mounting post or bolt 32 extendingupwardly and through a mounting hole 34 within a staggered clamp 36. Thestaggered clamp 36 includes a contact ledge 37. A nut 38 is threadablycoupled to the mounting post 32 to force the contact ledge 37 of thestaggered clamp 36 downwardly against the peripheral margin of the solarpanel 11, thus locking the position of the solar panel 11. Thetightening of the nut 38 upon the post 32 also causes the staggeredclamp 36 to be forced downward into abutment with the upper member 26 ofthe I-beam, thereby locking the position of the C-shaped bracket 30 andstaggered clamp 36 relative to the I-beam 24. The base plate 14, I-beam24, bracket 30, and clamp 36 may all be made of a polymer or metalmaterial, such as aluminum.

Lastly, the mounting system 10 includes a weld harness or weld harnessstrip 39 and anti-creep strips 44 which are coupled to the base member17 through bolts 40. As with all embodiments herein, the anti-creepstrips 44 include a generally planar support 45 and an array orarrangement of downwardly extending feet or projections 46. Theanti-creep strip 44 may be made of a polymer material or the like. Theweld harness strip 39 has a first portion 39′ which is coupled to thebase plate 14, and a second portion 39″ which is meltable to theunderlying tufted geosynthetic 41.

In use, the weld harness strip 39 overlays a portion of the tuftedgeosynthetics 41 wherein heat, or other form of welding, is applied tothe weld harness strip 39 so that the weld harness strip 39 partiallymelts or becomes molten and thereby bonds or coupled with the strands oryarns 42 of the geosynthetic material when cooled. The bonding of theweld harness strip 39 to the yarns is depicted by welding reference W.

It should be understood that the geosynthetic material may be used incombination with one or more layers of additional geosyntheticmaterials.

With reference next to FIGS. 9 and 10, there is shown a portion of adouble glass solar panel 11 with a side edge mounting bracket 50. Here,the side edge mounting bracket 50 has a U-shaped member 52 and amounting flange 54 extending laterally and horizontally from theU-shaped member 52. The mounting flange 54 includes one or more mountingholes 56. The member 52 grips a side portion of the solar panel 11, andmay be secured thereto with fasteners or adhesive.

The side edge mounting bracket 50 may be coupled to mechanical meansshown in FIG. 8. Specifically, the side edge mounting bracket 50 may becoupled to the C-shaped bracket 30 with the mounting post 32 extendingthrough one of the mounting holes 56 of the mounting flange 54 andsecured thereto with a mounting nut 38. As with the embodiment of FIG.8, the C-shaped bracket 30 is coupled to the I-beam 24 which in turn iscoupled to the base plate 14. The welding harness strip 39 andanti-creep strip 44 are also utilized to prevent relative movement withrespect to the geosynthetic material to which the welding harness stripis mounted. Again, the welding harness strip may be mounted through heatwelding, ultrasonic welding, adhesive, or mechanical means such as a nutand bolt. However, heat or ultrasonic welding is preferred as itprovides a superior bond between the yarn of the preferred tuftedgeosynthetic material.

With reference next to FIGS. 11 and 12, there is a shown a solar panel11 and mounting system 60 in another preferred form of the invention.Here, the mounting system 60 includes a side edge mounting bracket 50similar to that shown in FIGS. 9 and 10. However, the mounting system 60includes a mounting rail or attachment 62 which essentially replaces theC-shaped bracket 30, I-beam 24 and base plate 14 of the previousembodiments. The mounting bracket 50 is captured within a channel 63within the mounting attachment 62 so as to be selectively releasablycoupled to and slideable relative to the mounting attachment 62. Themounting attachment 62 may be made of any suitable material, such as ametal or polymer.

Here, the mounting attachment 62 includes a top portion 64 whichcaptures the mounting flange 54 of the side edge mounting bracket 50extendingly attached to the solar panel 11 and is affixed thereto andsecured in position through a threaded mounting bolt 38. Optionally, themounting attachment 62 may be made of a polymer material which allows itto flex, thereby allowing for the solar panel to be snap fitted into thetop portion 64 without the need for the use of the mounting post and nutto secure the position of the solar panel 11 to the mounting attachment62. The top portion 64 extends to and merges with a lower portion orcradle 66 which extends about the side and bottom of the mountingbracket 50. The lower portion 66 may be considered to be an elongatedbase plate or base portion and is integrally coupled with or extendingfrom the mounting attachment 62. The lower portion 66 includes feet 68to which the anti-creep strip 44 is coupled through conventional means,such as bolts, screws, or adhesive. The lower portion 66 also includesweld harness strips 39 which are welded W or otherwise coupled to thetufted geosynthetic material, and specifically the yarns of the tuftedgeosynthetic material, as previously discussed.

The lowest part of lower portion 66 may be considered to be a base plateas it forms the base of the lower portion 66. Therefore, the highestpart of lower portion 66, which forms the C-shaped channel about bracket50, may be considered to be an elongated rail which is integrally formedwith or extends from the portion considered to be the base plate.

With this configuration, ballast B, such as elongated weight members,may be easily coupled to the mounting attachment 62 if desired, as shownin FIG. 12.

Multiple mounting attachments may be mounted end to end, as shown inFIG. 12, to form a compart series of solar panels 11 and mountingsystems 10.

With reference next to FIG. 13, there is shown a solar panel 11 andmounting system 70 in another preferred form of the invention. Here, aweld harness strip 72 is mounted directly to a side edge mountingbracket 74. The weld harness strip 72 includes mounting holes 76 whichare aligned with mounting holes 78 in the side edge mounting bracket 74.A fastener 79, such as a mounting bolt, is passed through the mountingholes 76 and 78. Anti-creep strips 80 may be attached to the bottom ofsolar panel 11.

In use, the weld harness strip 72 is once again welded to the strands oryarns of the underlying tufted geosynthetic material, as previouslydiscussed.

With reference next to FIGS. 14-16, there is shown a wire tray system 90for a solar panel mounting system for tufted geosynthetic material in apreferred form of the invention. The wire tray system 90 includes ahollow conduit 91 having a top portion 92 and a bottom portion 93 snapfitted to top portion 92, the conduit 91 forming a channel C throughwhich the wiring of the solar panels may be positioned. The wire traysystem 90 also includes a base, foot or stand 94 which is snap fitted tothe conduit 91.

The top portion 92 is generally a half cylinder having ends 95 in theform of tangs that are releasably received within longitudinal grooves96 along the upper ends of the bottom portion 93. The bottom portion 93also being in the form of a half cylinder and includes longitudinalstand grooves 99.

The stand 94 has a bottom portion 94′ is generally triangular in shapeand includes an anti-creep strip 96 coupled to the bottom surface of thestand 94. The stand bottom portion 94′ also includes oppositely disposedweld harness strips 97. Lastly, the stand bottom portion 94′ includes apair of oppositely disposed longitudinal catches 100 which areconfigured to be releasably received within the longitudinal grooves 99of the conduit bottom portion 93.

In use, the weld harness strips are welded or otherwise coupled to theyarn of the tufted geosynthetic material, as previously discussed.Again, the anti-creep strip 96 prevents relative movement of the wiretray system 90 relative to the tufted geosynthetic material.

The conduit top portion 92 may be easily released from the conduitbottom portion 93 to provide easy access to the wiring within theconduit 91. Also, the entire conduit 91 may be easily removed from thestand 94 for replacement purposes.

With reference next to FIGS. 17 and 18, there is a shown a solar panel11 and mounting system 110 in another preferred form of the invention.Here, the mounting system 110 includes a side edge mounting bracket 112which may be formed as part of the solar panel 11, but whichalternatively may be formed similar to bracket 50 shown in FIGS. 9 and10. The mounting bracket 112 includes a mounting hole 113 therethrough.In this embodiment, the mounting system 110 includes ballast; therefore,the need for a welding strip is optional.

The system 110 includes a generally U-shaped, elongated base plate 114having an elongated mounting slot or channel 116 defined by a generallyplanar, elongated base member 117 and two oppositely disposed elongated,vertically oriented channel walls 118 having inwardly extending lips orflanges 119. The base member 117 includes a series of elongated mountingholes 120. It should be understood that the system includes pairs oflike components to complete the system, i.e., pairs of base members 117,spacers beams 124, corresponding fasteners, and the like.

The system also includes an elongated U-shaped spacer beam or rail 124having a horizontal lower member 125, two oppositely disposed side walls126 each having an inwardly extending lip or flange 127 defining a slotor channel 128 therebetween. The lower member 125 has mounting holes 129therethrough. A first T-shaped fastener 131 having an elongated mountingplate 132 and an externally threaded mounting post 133 which extendsthrough the spacer beam mounting hole 129 and is threadably coupled toan internally threaded first mounting nut 134. The spacer beam 124 isselectively, releasably coupled to and slideable relative to theunderlying and longitudinally aligned base member 117 for slideablemovement therebetween through a force placed upon the spacer beam 124through the loosening of first mounting nut 134 and locked in place bythe tightening of first mounting nut 134. The width of the mountingplate 132 is slightly smaller than the size (width) of the mounting slot116 while the length of the mounting plate 132 is larger than the size(width) of the mounting slot 116, so that the mounting plate 132 may bepassed through the slot 116 and then rotated so that it then cannot passback through the slot 116. The corners of the mounting plate 132 arerounded so that they may bear against the interior surface of thechannel walls 118.

A second T-shaped fastener 137 having an elongated mounting plate 138and an externally threaded mounting post 139 is coupled to the spacerbeam 124. The threaded mounting post 139 extends through the slot 128,through the mounting hole 113 in mounting bracket 112 and is threadablycoupled to an internally threaded second mounting nut 140. The solarpanel 11 is selectively, releasably coupled to and slideable relative tothe underlying spacer beam 124 for slideable movement therebetween formounting and adjustment purposes through the loosening of secondmounting nut 140 and locked in place by the tightening of secondmounting nut 140. The width of the mounting plate 138 is slightlysmaller than the size (width) of the mounting slot 128 while the lengthof the mounting plate 138 is larger than the size (width) of themounting slot 128, so that the mounting plate 138 may be passed throughthe slot 128 and then rotated so that it then cannot pass back throughthe slot 128. The corners of the mounting plate 138 are rounded so thatthey may bear against the interior surface of the spacer beam side walls126.

The mounting system 110 also includes a ballast system 145 which isreleasably and slideably coupled to the base member 117. The ballastsystem 145 includes a ballast tray 146 having a floor 147, twooppositely disposed side walls 148 and a mounting flange 149 extendingoutwardly from each side wall 148. Each mounting flange 149 has twomounting holes 150 therethrough. One of more ballast modules 152,preferably in the form of concrete slabs, may be positioned upon thefloor 147 of the ballast tray 146, to provide adequate weight to preventthe solar panels 11 and the mounting system 110 from being displaced.The ballast tray 146 may be made of a metal or other suitable material.

A third T-shaped fastener 155 having an elongated mounting plate 156 andan externally threaded mounting post 157 which extends through theballast tray mounting hole 150 and is threadably coupled to aninternally threaded third mounting nut 158. The ballast tray 146 isselectively, releasably coupled to and slideable relative to theunderlying base member 117 for slideable movement therebetween through aforce placed upon the ballast tray 146 through the loosening of thirdmounting nut 158 and locked in place by the tightening of third mountingnut 158. The width of the mounting plate 156 is slightly smaller thanthe size (width) of the mounting slot 116 while the length of themounting plate 156 is larger than the size (width) of the mounting slot116, so that the mounting plate 156 may be passed through the slot 116and then rotated so that it then cannot pass back through the slot 116.The corners of the mounting plate 156 are rounded so that they may bearagainst the interior surface of the channel walls 118.

Lastly, the mounting system 110 includes anti-creep strips 161 which arecoupled to each base member 117 through fourth T-shaped fasteners 162.The anti-creep strips 161 include a generally planar support 163 and anarray or arrangement of downwardly extending feet or projections 164.The anti-creep strip 161 may be made of a polymer material or the like.The fourth T-shaped fastener 162 have an elongated mounting plate 166and an externally threaded mounting post 167 which extends through thebase member elongated mounting holes 120 and is threadably coupled to aninternally threaded fourth mounting nut 168. The width of the mountingplate 166 is slightly smaller than the size (width) of the mounting slot116 while the length of the mounting plate 166 is larger than the size(width) of the mounting slot 116, so that the mounting plate 166 may bepassed through the slot 116 with the mounting post 167 extending throughthe elongated mounting hole 120 and secured with fourth nut 168 tosecure the anti-creep strip 161 to the base plate 114. The corners ofthe mounting plate 132 are rounded so that they may bear against theinterior surface of the channel walls 118.

It should be understood that the first, second, third and fourthT-shaped fasteners 131, 137, 155, and 162 are preferably all the same toprovide less inventory and easy exchange of pieces. These fasteners passthrough the slots or holes (113, 116, and 128) and bind upon rotation sothat they do not need to be held in place with a tool duringinstallation, as shown in FIG. 20.

In use, the anti-creep strip 161 prevents relative movement of themounting system 110 relative to the tufted geosynthetic material. Thearray of downwardly extending feet or projections 164 inter-engage withthe tufts for frictionally resisting movement relative to the tuftedgeosynthetic.

With reference next to FIG. 19, there is a shown a solar panel 11 andmounting system 210 in another preferred form of the invention. Here,the mounting system 210 is essentially the same as that shown inreference to FIGS. 17 and 18 except that the spacer beam 124 and itscorrelating parts are not included.

With the absence of the spacer beam 124, the first T-shaped fastener 131is coupled directly to the solar panel 11 with the mounting post 133extending through the mounting hole 113 within the solar panel mountingbracket 112. The first mounting nut 134 is threaded upon the mountingpost 133 to secure the solar panel 11 in place. This configuration maybe preferred when a large amount of ventilation below the solar panel isnot required.

FIG. 21 illustrates an end view of an alternate embodiment of themounting system shown in FIG. 17, using a one-piece extruded rail 251(as the base plate referenced above). The rail 251 comprises anelongated member having at least one web 253 attached to opposing sidewalls 255. The illustrated embodiment includes a pair of webs 253. Thesides walls 255 define a channel 256 and opposing profiles for a base257 for contacting the attaching connection 188 and an opposing seat 259for connecting to the bracket 112 of the photovoltaic module 11. Thebracket 112 may be integral with the photovoltaic module 11 as suppliedby the module manufacturer, or may be part of a Y-shaped bracket similarto bracket 50 shown in FIGS. 9 and 10 for engaging a side edge of themodule.

The side walls 255 have inwardly extending lips or flanges 261,respectively, and each pair defines a respective slot 263 therebetweenfor the base 257 and for the seat 259. A plurality of fasteners 162secure the rail 251 to the anti-creep strip 161. The post of thefastener extends though the slot 263 and through the anti-creep strip161. Upon rotating, the plate 166 on the flanges 261 bears on the sidewalls 255, and the nut 168 threads on the post to secure the attachingconnection 188 to the rail 251. The feet 164 extending from theanti-creep strip than engages the tufts 215 of the geosynthetic cover11. The photovoltaic module 3 then rests with the bracket 112 on theseat 259. A post 133 of a fastener 131 extends upwardly through the slot263 in the seating end 259, and through the opening in the bracket 112.The plate 132 rotates into engagement with the side walls 255. The nut134 threadably engages the post 133 to secure the photovoltaic module 11to the rail. Although not illustrated, a spring attached to the platemay assist by holding the plate between the web 253 and the flanges 261in contact with the flanges 261 until the nut secures the fastener tothe rail.

It should be understood that in these embodiments the weld harness stripis preferably made of a polyethylene material. Similarly, the yarns ofthe tufted geosynthetic material are also made of a polyethylenematerial. With this construction, the melting point of the weld harnessstrip is generally that of the yarns of the tufted geosyntheticmaterial, thereby creating a superior bold or weld there between.However, it should be understood that other types of polymer materialsmay also be used for these components without departing from the scopeof the invention.

The distinct advantage to the invention described in the multipleembodiments herein is that the solar panels may be positioned orarranged in a manner that provides for a higher density of solar panelsper area of land. This higher density allows for the generation of moreelectricity per land area. Another advantage is the easy of mountingsolar panels without the need for a racking system or without theoccurrence of panel movement over time.

The wind breaking element, such as members 219, readily attach to thephotovoltaic module 3, or alternatively, to the bracket 50 or 112, forwind uplift resistance, by creating turbulent flow near the surface ofthe cover, thus greatly reducing the actual wind velocity at the coversurface and decreasing associated uplift.

In all embodiments wherein two base plates, spacers, or rails are shown,it should be understood that the invention may include at least one suchcomponent, however, such an arrangement is not preferred.

This invention has been described with particular reference to certainembodiments, but variations and modifications can be made withoutdeparting from the spirit and scope of the invention.

1. An integrated photovoltaic module mounting system for use in mountinga photovoltaic module to tufted geosynthetics, comprising: at least oneelongated base plate; at least one elongated rail, said elongated railcoupled to and longitudinally aligned with said base plate; a pluralityof rail fasteners coupling said base plate and said elongated rail; aplurality of photovoltaic module fasteners coupling said rail with thephotovoltaic module, and an anti-creep strip coupled to a bottom surfaceof said base plate.
 2. The integrated photovoltaic module mountingsystem of claim 1 wherein said base plate includes an elongated baseplate slot and wherein said rail fasteners include a mounting platehaving a selected width smaller than the width of said base plate slotand a length larger than the width of said base plate slot.
 3. Theintegrated photovoltaic module mounting system of claim 2 wherein saidelongated rail includes an elongated rail slot and wherein saidphotovoltaic module fasteners include a mounting plate having a selectedwidth smaller than the width of said rail slot and a length larger thanthe width of said rail slot.
 4. The integrated photovoltaic modulemounting system of claim 1 wherein said elongated rail includes anelongated rail slot and wherein said photovoltaic module fastenersinclude a mounting plate having a selected width smaller than the widthof said rail slot and a length larger than the width of said rail slot.5. The integrated photovoltaic module mounting system of claim 1 furthercomprising a plurality of anti-creep strip fasteners with a mountingplate having a selected width smaller than the width of said base plateslot and a length larger than the width of said base plate slot.
 6. Anintegrated photovoltaic module mounting system for use in mounting aphotovoltaic module to tufted geosynthetics, comprising: at least oneelongated rail; a plurality of first fasteners coupling said rail withthe photovoltaic module; and an anti-creep strip coupled to a bottomsurface of said rail.
 7. The integrated photovoltaic module mountingsystem of claim 6 wherein said rail includes an elongated slot andwherein said first fasteners include a mounting plate having a selectedwidth smaller than the width of said slot and a length larger than thewidth of said slot.
 8. The integrated photovoltaic module mountingsystem of claim 6 further comprising an elongated second rail, saidelongated second rail being coupled to said rail and a plurality ofsecond fasteners coupling said rail with said elongated second rail, andwherein the photovoltaic module is coupled to said rail through saidelongated second rail and said plurality of second fasteners.
 9. Theintegrated photovoltaic module mounting system of claim 8 wherein saidelongated second rail includes an elongated rail slot and wherein saidsecond fasteners include a mounting plate having a selected widthsmaller than the width of said rail slot and a length larger than thewidth of said rail slot.
 10. The integrated photovoltaic module mountingsystem of claim 7 further comprising a plurality of second fastenerscoupling said rail to said anti-creep strip, each said second fastenerincludes a mounting plate having a selected width smaller than the widthof said base plate slot and a length larger than the width of said slot.11. An integrated photovoltaic module mounting system for use inmounting a photovoltaic module to tufted geosynthetics, comprising: atleast one elongated base plate, said base plate having a base member,two opposing side walls each having an inwardly extending lip to definea base plate slot therebetween having a selected slot width; a pluralityof first fasteners coupling said base plate with the photovoltaicmodule, said first fasteners having a mounting plate with a selectedwidth less than said selected slot width and a selected length greaterthan said selected slot width; and an anti-creep strip coupled to abottom surface of said base plate, said anti-creep strip including asupport and a plurality of projections depending downwardly from saidsupport.
 12. The integrated photovoltaic module mounting system of claim11 further comprising at least one elongated rail, said rail couplingsaid base plate to the photovoltaic module, and a plurality of secondfasteners coupling said base plate to said elongated rail.
 13. Theintegrated photovoltaic module mounting system of claim 12 wherein saidrail includes an elongated rail slot and wherein said second fastenersinclude a mounting plate having a selected width smaller than the widthof said rail slot and a length larger than the width of said rail slot.14. The integrated photovoltaic module mounting system of claim 13further comprising a plurality of third fasteners coupling saidanti-creep strip to said base plate, each said third fastener having amounting plate having a selected width smaller than the width of saidbase plate slot and a length larger than the width of said base plateslot.
 15. A method of mounting a photovoltaic module for use with tuftedgeosynthetics, comprising the steps of: (a) coupling an anti-creep stripto a bottom surface of an elongated rail; (b) positioning the anti-creepstrip onto a portion of a tufted geosynthetics covering a surface; and(c) coupling a photovoltanic module to the elongated rail, wherein thephotovotanic module generates electricity and the anti-creep stripinter-engaged with the tufts of the tufted geosynthetics resists winduplift.